Vehicle exterior mirror system with turn signal light assembly

ABSTRACT

A mirror assembly security system for a vehicle includes an exterior mirror assembly and a light module removably positioned within the exterior mirror housing. The light module is moisture impervious and includes an enclosure, a light-transmitting opening in the enclosure facing generally downwardly and/or rearwardly of the vehicle, a cover for the light-transmitting opening, and a light source in the enclosure radiating light through the light-transmitting opening. The light source may be received in a socket which removably engages another opening in the enclosure. In this manner, the light source may be replaced by removing the module from the exterior mirror housing, removing the socket from the enclosure and replacing the light source. The enclosure and mirror housing preferably are configured to self-retain the module in the exterior mirror moving with no, or fewer than one or two, separate fasteners.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application under 37 CFR 1.53 ofapplication Ser. No. 10/905,121, filed Dec. 16, 2004, now U.S. Pat. No.7,325,953, which is a continuation of application Ser. No. 09/967,236,filed Sep. 28, 2001, now U.S. Pat. No. 6,832,848, by Todd W. Pastrick,entitled VEHICLE EXTERIOR MIRROR SYSTEM WITH TURN SIGNAL LIGHT ASSEMBLY,which is a continuation of application Ser. No. 09/596,015, filed onJun. 16, 2000, now U.S. Pat. No. 6,296,379, which is a continuation ofapplication Ser. No. 09/259,815, filed on Feb. 26, 1999, now U.S. Pat.No. 6,086,229, which is a continuation of application Ser. No.08/933,375, filed on Sep. 19, 1997, now U.S. Pat. No. 5,879,074, whichis a continuation of application Ser. No. 08/607,284, filed on Feb. 26,1996, now U.S. Pat. No. 5,669,704, which is a continuation ofapplication Ser. No. 08/426,591, filed on Apr. 21, 1995, now U.S. Pat.No. 5,497,306, which is a continuation-in-part of application Ser. No.08/333,412, filed Nov. 2, 1994, now U.S. Pat. No. 5,497,305, which is acontinuation of application Ser. No. 08/011,947, filed Feb. 1, 1993, nowU.S. Pat. No. 5,371,659.

BACKGROUND OF THE INVENTION

This invention relates generally to security systems for vehicles and,more particularly, to remotely actuated, personal safety lightingsystems. The invention is particularly adapted to incorporation in theexterior mirrors of a vehicle.

Personal security in and around vehicles has become an importantconcern. In particular, an increasing number of assaults and robberiesare committed in parking lots while occupants are entering and exitingvehicles. While remote-operated, keyless entry systems have beenincorporated in vehicles in order to unlock the vehicle and illuminateinterior lights, such systems merely expedite entry to the vehicle anddo not, per se, enhance security around the vehicle. Accordingly, a needexists for a vehicle security system to increase the security forvehicle occupants while entering and exiting the vehicle. Any suchsystem would need to be aesthetically pleasing and not burdensome inuse.

In order to include a security light system in a vehicle exterior mirrorassembly, the security light must be rugged and resistant toenvironmental conditions such as water splash from road surfaces, rainand other precipitation as well as car washes. The assembly desirablymust additionally be of relatively low cost and easy to manufacture inorder to be acceptable to vehicle manufacturers. In addition, thesecurity light desirably must be capable of matching a multiplicity ofmirror housing designs. Moreover, the security light desirably iscompact so as to fit into the interior cavity of conventional exteriormirror housings. For styling and aerodynamic reasons, exterior mirrorhousings are of determined and restricted size, shape, design, andinterior volume. Moreover, the interior volume is already typicallyrelatively cramped as it must accommodate not only the mirror reflectorelement itself and its movement, but also usually a manual or electricactuator that allows adjustment of the rearward field of view of thereflector remotely by the driver from the interior cabin of the vehicle.Also, since it is commercially desirable for a manufacturer of asecurity light to supply to a multitude of exterior mirrormanufacturers, for their incorporation into their own particularexterior mirror assembly construction, it is desirable that the light beof a module type that is compact; that is weatherproofed; that isattachable and receivable by a wide variety of exterior mirror assemblydesigns; that is readily, standardly, and conveniently connectable tothe vehicle electrical service and wiring already commonly found inconventional exterior mirror assemblies; and that is economic both formanufacture by the light module manufacturer and for the manufacturer ofthe complete exterior mirror assembly who will incorporate the lightmodule into a mirror housing.

Importantly, the security light must be easy to service. The vehiclerepair technician must be provided with easy access to the light sourcein order to replace the light source during the useful life of thevehicle. Furthermore, the light source should be replaceable withoutremoving and subsequently replacing numerous fasteners. Such fastenersare not only time-consuming to remove and replace, but are subject togetting lost as well as damaged. Most or all of the above requirementsmust be met in order to have a commercially viable vehicle exteriormirror assembly security system suitable for use on a vehicle, such asan automobile. Indeed, the Applicants do not know of any successfulcommercial incorporation of a light module into an exterior mirrorassembly on an automobile and believe that their inventions are thefirst commercially successful applications of a light module suitablefor use in the exterior mirror assembly on an automobile.

SUMMARY OF THE INVENTION

The present invention is intended to provide a personal safety featurefor a vehicle in the form of a light adapted to projecting lightgenerally downwardly on an area adjacent a portion of the vehicle inorder to create a lighted security zone in the area. Advantageously, thelight, that preferably provides a security function, is provided as amodule that is suitable for use in the exterior mirror housing designsof various vehicles. The light module is capable of low cost, easymanufacture. Furthermore, the module is compact and is substantiallymoisture impervious in order to resist environmental forces.Advantageously, the light module is easy to service in order to replacethe light source by requiring a minimum of, preferably one or no,fasteners in order to remove the module from the exterior mirrorassembly. Furthermore, the invention encompasses a signal light modulewith the advantages described above and with the signal light generatinga light pattern discernable to drivers of overtaking vehicles butlargely imperceptible to the driver of the vehicle on which the signallight itself is mounted.

According to an aspect of the invention, a mirror assembly securitysystem for a vehicle includes an exterior mirror assembly having areflective element and a housing for the reflective element. A lightmodule is removably positioned within the housing. The light moduleprojects light from the housing on an area adjacent a portion of thevehicle, preferably in order to create a lighted security zone in thatarea. The light module includes an enclosure, a light-transmittingopening in the enclosure facing downwardly or rearwardly of the vehicle,or both, a cover for the light-transmitting opening, and a light sourcein the enclosure. The light module may further include a serviceable,removable light source receiving means, such as a socket positioned inanother opening in the enclosure and a gasket for sealing the socket inthe opening, or with the mating surface of the socket to the openingbeing self-gasketing. In this manner, the light source can be replacedby removing the light module from the exterior mirror housing andremoving the socket from the light module. The light module and themirror housing may have mating surface configurations, which at leastpartially retain the light module in the housing. This may eliminate therequirement for multiple fasteners which must be removed in order toservice the light module.

The light module may further include a second light-transmitting openingin the enclosure facing rearwardly of the vehicle, a second cover forthe second light-transmitting opening, and a second light source in thesecond enclosure radiating light through the second light-transmittingopening. This feature may provide a signal light for use as either aturn signal, a brake signal, or both, visible from the side of theequipped vehicle. In a preferred embodiment, the second light source isa plurality of light-emitting diodes and includes louvers between thelight-emitting diodes. The louvers may be skewed in a direction awayfrom the vehicle passenger compartment in order to shield the driverfrom light radiated by the light-emitting diodes.

The light module is preferably substantially moisture impervious inorder to be resistant to environmental elements. The enclosure ispreferably a unitary assembly with the lens covering thelight-transmitting opening permanently joined with the remainder of theenclosure. The light source is preferably serviceably, movably receivedwithin the enclosure by a socket that engages in an opening in theenclosure. In this manner, the light source may be replaced by removingthe light module from the exterior mirror housing, removing the socketfrom the enclosure and replacing the light source in the socket.

The invention provides a universal configuration for a mirror assemblysecurity system, which allows the vehicle manufacturer to offer a mirrorassembly system having only the security light feature, which projectslight from the housing on an area adjacent a portion of the vehicle inorder, for example, to create a lighted security zone in that area.Alternatively, the invention allows the vehicle manufacturer to offer amirror assembly having an additional or a stand-alone signal light; forexample, a turn signal, a brake light, or both a turn signal and a brakelight. The signal light increases security for the vehicle occupant byproviding signals to vehicles overtaking the equipped vehicle from theside. The signal light may be designed to be observed by other vehiclespassing the equipped vehicle, but not directly by the driver of theequipped vehicle.

The security system is adapted to projecting a pattern of light from theexterior mirror housing on an area adjacent a portion of the vehiclethat extends laterally onto the vehicle and downwardly and rearwardly ofthe vehicle. In this manner, a security zone is established in thevicinity of the vehicle doors where occupants enter and exit thevehicle. The signal light is adapted to projecting a pattern of lightextending laterally away from the vehicle and rearwardly of the equippedvehicle. In this manner, the pattern generated by the signal lightcannot be substantially observed by a driver of the equipped vehicle.However, the pattern generated by the signal light may be observed by adriver of another vehicle passing the vehicle equipped according to theinvention.

By providing a lighted security zone adjacent the vehicle, users canobserve suspicious activity around the vehicle. The pattern of lightgenerated by a security light according to the invention establishes asecurity zone around, and even under, the vehicle in the important areawhere the users enter and exit the vehicle. The invention, further,conveniently combines a signal light that acts in unison with thevehicle's turn signal, brake light, or both, with the security light, oras a stand-alone accessory, in an exterior mirror assembly. The signallight may be designed to be observed by other vehicles passing theequipped vehicle but not directly by the driver of the equipped vehicle.

These and other objects, advantages and features of this invention willbecome apparent upon review of the following specification inconjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view taken from the front of a mirror assembly(rear of the vehicle) incorporating the invention;

FIG. 2 is a rear view of the mirror assembly in FIG. 1;

FIG. 3 is a top view of the mirror assembly in FIG. 1;

FIG. 4 is the same view as FIG. 1 of an alternative embodiment of theinvention;

FIG. 5 is a block diagram of a control system according to theinvention;

FIG. 6 is a block diagram of an alternative embodiment of a controlsystem according to the invention;

FIG. 7 is a breakaway perspective view of the system in FIG. 1 revealinginternal components thereof;

FIG. 8 is a sectional view taken along the lines VIII-VIII in FIG. 7;

FIG. 9 is a sectional view taken along the lines IX-IX in FIG. 7;

FIG. 10 is a side elevation of a vehicle illustrating the security zonelight pattern generated by a security light according to the invention;

FIG. 11 is a top plan view of the vehicle and light pattern in FIG. 10;

FIG. 12 is a rear elevation of the vehicle and light pattern in FIG. 10;

FIG. 13 is a side elevation of a vehicle illustrating the light patterngenerated by a signal light useful with the invention;

FIG. 14 is a top plan view of the vehicle and light pattern in FIG. 13;

FIG. 15 is a rear elevation of the vehicle and light pattern in FIG. 13;

FIG. 16 is the same view as FIG. 7 of a first alternative light sourceaccording to the invention;

FIG. 17 is the same view as FIG. 7 of a second alternative light source;

FIG. 18 is the same view as FIG. 7 of a third alternative light source;

FIG. 19 is the same view as FIG. 7 of a fourth alternative light source;

FIG. 20 is the same view as FIG. 7 of the invention embodied in analternative mirror structure;

FIG. 21 is an exploded perspective view taken from the front of a mirrorassembly (rear of the vehicle), according to another aspect of theinvention;

FIG. 22 is an exploded perspective view illustrating details of thelight module;

FIG. 23 is a sectional view taken along the lines XXIII-XXIII in FIG.22;

FIG. 24 is a front elevation of the mirror assembly in FIGS. 21 and 22illustrating the manner in which a light module is removably mounted toan exterior rearview mirror housing;

FIG. 25 is the same view as FIG. 23 of an alternative embodiment;

FIG. 26 is an exploded perspective view taken from the front of a mirrorassembly of another alternative embodiment of the invention;

FIG. 27 is a sectional view taken along the lines XXVII-XXVII in FIG.26;

FIG. 28 is a sectional view taken along the lines XXVIII-XXVIII in FIG.26;

FIG. 29 is the same perspective view as FIG. 22 of another alternativeembodiment;

FIG. 30 is a front elevation of the mirror assembly in FIG. 29illustrating the light module mounted to the support bracket; and

FIG. 31 is a sectional view taken along the lines XXXIII-XXXIII in FIG.30.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now specifically to the drawings, and the illustrativeembodiments depicted therein, a vehicle personal security lightingsystem 25 includes an exterior mirror assembly 26 having a conventionalreflectance element 28, a security light 30, preferably white, or clear,and a signal light 32, preferably red or red-orange, incorporated in ahousing, or casing, 34. Casing 34 is connected by a neck 36 to astationary panel or sail 38 adapted for incorporation with the forwardportion of the vehicle side window assembly, and which mounts mirrorassembly 26 to the door of a vehicle 40 (see FIG. 10). Reflectanceelement 28 may be any of several reflectors, such as glass coated on itsfirst or second surface with a suitable reflective layer or layers, suchas those disclosed in U.S. Pat. No. 5,179,471, the disclosure of whichis hereby incorporated by reference herein, or an electro-optic cellincluding a liquid crystal, electrochromic, or electrochemichromicfluid, gel or solid-state compound for varying the reflectivity of themirror in response to electrical voltage applied thereacross asdisclosed in U.S. Pat. No. 5,151,824, the disclosure of which is herebyincorporated by reference herein.

With reference to FIGS. 7 and 8, as is conventional, reflectance element28 is mounted to a bracket 43 by a positioning device such as anactuator 42. Casing 34 is mounted to bracket 43. Actuator 42 providesremote positioning of reflectance element 28 on two orthogonal axes.Such actuators are well known in the art and may include ajackscrew-type actuator 42 such as Model No. H16-49-8001 (right-handmirror) and Model No. H16-49-8051 (left-hand mirror) by Matsuyama ofKawagoe City, Japan, as illustrated in FIG. 7, or a planetary-gearactuator 42′ such as Model No. 540 (U.S. Pat. No. 4,281,899) sold byIndustrie Koot BV (IKU) of Montfoort, Netherlands, as illustrated inFIG. 20. As is also conventional, the entire casing 34 includingactuator 42, 42′ is mounted via bracket 43 for breakaway motion withrespect to stationary panel 38 by a breakaway joint assembly 44.Breakaway joint assembly 44 (FIG. 9) includes a stationary member 46attached to vehicle 40, a pivoting member 48 to which bracket 43 andcasing 34 are attached, and a wire-way 50 through which a wire cable 52passes. Wire cable 52 includes individual wires to supply controlsignals to actuator 42, 42′, as well as signals to control the level ofreflectivity, if reflective element 28 is of the variable reflectivitytype noted above, such as an electrochromic mirror. Power may also besupplied through cable 52 for a heater 53 as disclosed in U.S. Pat. No.5,151,824 in order to evaporate ice and dew from reflective element 28.

With reference to FIG. 5, actuator 42, 42′ receives a first set ofreversible voltage signals from a switch 54, in order to bidirectionallypivot in one axis, and a second set of reversible signals from a switch56, in order to bidirectionally pivot in the opposite axis, as isconventional. Switches 54 and 56 are actuated by a common actuator (notshown) that is linked so that only one of the switches 54 and 56 may beactuated at a time. In this manner, actuator 42, 42′ may utilize onecommon conductor for both switches 54, 56.

Each of the security light 30 and signal light 32 includes a lightsource 60 and reflector 62 behind a lens 64 (FIG. 8). Light source 60,reflector 62 and lens 64 are designed for security light 30 to project apattern 66 of light, such as white light, through a clear, non-filteringlens, in order to establish a security zone around the vehicle (FIGS.10-12). Pattern 66 extends rearward from mirror assembly 26. Vertically,pattern 66 contacts the ground at 68 in the vicinity of entry and exitby the vehicle occupants (FIGS. 10 and 12). Laterally, pattern 66 fansout into contact with the side 70 a, 70 b of the vehicle. This contactwashes the sides of the vehicle to reflect the light in order to furtherilluminate the area in order to establish the security lighting zone(FIGS. 11 and 12). In a preferred embodiment, pattern 66 extendsrearwardly from mirror assembly 26 without projecting any portion of thepattern forwardly of the mirror assembly.

Signal light 32 generates a light pattern 72, which is directedgenerally horizontally rearwardly of vehicle 40 (FIGS. 13-15). Pattern72 is laterally directed substantially away from side 70 a, 70 b ofvehicle 40 so that the driver of vehicle 40 does not directly interceptpattern 72, although a minor intensity (such as 10%) of the pattern isintercepted by the driver in order to provide awareness of the actuatingof the signal light. Pattern 72 fans laterally away from side 70 a, 70 bto an extent that is parallel the face of reflectance element 28, whichis substantially perpendicular to side 70 a, 70 b (FIG. 14). Thus, thedriver of another vehicle (not shown) passing vehicle 40 on the left orright side of vehicle 40 will intercept pattern 72 while the vehicle isbehind and beside vehicle 40. Although, in the illustrated embodiment,lens 64 of signal light 32 is substantially planar, lens 64 of signallight 32 could be made to wrap around the outward side of casing 34 inorder to function as a side marker for the vehicle as is required insome European countries.

Vehicle mirror assembly security system 25 is actuated by a controlsystem 74 (FIG. 5). Control system 74 includes means for actuatingsecurity light 30 including a remote transmitting device 76 and astationary receiving device 78. Transmitting device 76 may be remotelycarried by the vehicle operator and includes switches 80 and 81 in orderto actuate the transmitting circuitry to transmit a signal from antenna82, which is received by antenna 84 of receiving device 78. Receivingdevice 78 is mounted in the vehicle, such as in the vehicle trunkcompartment, interior cabin, or within or on a mirror assembly, andincludes an output 86 in order to operate remote door lock circuit 88,as is conventional. For example, an antenna, such as a metallic antennacomprising, for example, 6 to 20 gauge copper wire, and/or an RF, IR,and the like signal receiving circuit, may be incorporated into one, andpreferably both, of the exterior mirror assemblies, or into the interiormirror assembly, or into vehicle glazing, trim items such as sunvisorsand overhead consoles, and their like. Such an antenna can be auxiliarymounted, integrally mounted, or insert molded into or onto, for example,the exterior mirror bracket, sail, housing, bezel, or visor, or could bepart of the light module. Such receiving system can be of the automatic,proximity detection type that automatically senses proximity andapproach of the vehicle owner by its automatic detection of thetransducer carried by the vehicle owner, without that vehicle ownerhaving necessarily to operate neither a button on a hand-held unit.Also, the receiver may be part of, or itself be, a proximity detectionsystem that activates and illuminates the light module of this inventionwhenever the vehicle is approached under conditions where vehiclesecurity is being detected and protected.

Output 86 is, additionally, provided as an input 90 of a lockout circuit92, whose output 94 is supplied to security lamp 30. Input 90 mayadditionally be actuated by a timeout circuit 96, which isconventionally supplied in a vehicle in order to dim the interiorlights, following a slight delay, after the occurrence of an event, suchas the opening and closing of the doors of the vehicle. Signal light 32is actuated on line 98 from either a turn indicator circuit 100 or astop lamp indicator circuit 102, both of which are conventionallysupplied with vehicle 40.

In operation, when the operator actuates switch 80 of transmittingdevice 76, receiving device 78 produces a signal on output 86 in orderto cause remote door lock circuit 88 to unlock the doors. Alternatively,actuation of switch 81 on remote transmitting device 76 causes receivingdevice 78 to produce a signal on output 86 to cause remote door lockcircuit 88 to lock the vehicle doors. The signal on output 86 actuatessecurity lamp 30 provided that lockout circuit 92 does not inhibit thesignal. Lockout circuit 92 responds to operation of the vehicle in orderto avoid actuation of security lamp 30 when the vehicle is in motion.Such lockout circuits are conventional and may be responsive to placingof the vehicle transmission in gear or sensing of the speed of thevehicle, or the like. The lockout circuit may also be included in thevehicle's ignition system, such that the security light is disabled whenthe engine is started and the vehicle is operating. Thus, the lamp willbe off when the ignition switch is turned to start the engine. Securitylamp 30 is also actuated, in response to interior lighting devicetimeout circuit 96, whenever the interior lights of the vehicle arebeing actuated by timeout circuit 96, provided that lockout circuit 92does not inhibit the signal from security lamp 30. This is provided inorder to allow security lamp 30 to be actuated in response to the entryto, or exit from, vehicle 40 without the operator utilizing transmittingdevice 76 to lock or unlock the doors. Signal lamp 32 is actuated inresponse to turn indicator circuit 100 whenever the operator moves theindicator stick in the direction of that particular signal lamp 32.Signal lamp 32 may additionally be actuated from stop lamp circuit 102in response to the driver actuating the vehicle's brakes.

In the embodiment illustrated in FIGS. 1 and 5, lens 64 of signal lamp32 is adapted to filter the light provided from lamp 32 so as to be redand is provided for vehicles 40 in which the stop lamps and rear turnindicator lamps are, likewise, red. Because signal lamp 32 shines red,pattern 72 is restricted from extending forward of the vehicle. This isin order to comply with regulations prohibiting red lights from causingconfusion with emergency vehicles by shining forward of the vehicle.

For vehicles having red stoplights and amber turn indicators in therear, a vehicle mirror security assembly 25′ includes an exterior mirrorassembly 26′ and a control system 74′ (FIGS. 4 and 6). Exterior mirrorassembly 26′ includes a security light 30′, preferably white or clear,and a pair of signal lights 32 a′ and 32 b′. Signal light 32 a′ is amberand is actuated directly from turn indicator circuit 100′. This ambercolor can be provided either by an amber light bulb or source, or afiltering lens providing an amber color. Signal light 32 b′ is red,red-orange or amber, as desired by the automaker, and is actuateddirectly from stop lamp circuit 102′. Each of the light patternsgenerated by signal lights 32 a′ and 32 b′ substantially correspond withlight pattern 72. The light pattern generated by security light 30′ issubstantially equivalent to pattern 66. With the exception that turnsignal indicator circuit 100′ actuates signal light 32 a′ and stop lampcircuit 102′ actuates signal light 32 b′, control system 74′ operatessubstantially identically with control circuit 74.

In the illustrated embodiment, light source 60, for both security light30 and signal light 32, may be supplied as a conventional incandescentor halogen lamp 60 a (FIG. 7). Alternatively, a conventionalincandescent fuse lamp 60 b may be used (FIG. 16). Alternatively, avacuum fluorescent lamp 60 c, which is available in various colors, maybe used (FIG. 17). Alternatively, a light-emitting diode 60 d may beused (FIG. 18). As yet a further alternative, a fiber optic bundle 104forming a light pipe may be positioned to discharge light behind lens64. Fiber optic bundle 104 passes through breakaway joint 44 in wire-way50 in order to transmit light from a source (not shown) within vehicle40. By way of example, lens 64 may be supplied as a clear lens, adiffuser lens, a segmented lens, a prismatic lens, or a Fresnel lens inorder to generate light patterns 66 and 72. Bracket 43 and breakawayjoint 44 are marketed by Donnelly Corporation, the present assignee, ofHolland, Mich. The remote actuator composed of remote transmittingdevice 76 and stationary receiving device 78 may be radio frequencycoupled, as is conventional. Alternatively, they may be infrared coupledas illustrated in U.S. Pat. No. 4,258,352.

Although the invention is illustrated in a mirror assembly utilizing anautomatic remote actuator, it may also be applied to manual remoteactuators and handset actuators. As previously set forth, reflectanceelement 28 may be conventional or may be supplied as an electrochromicself-dimming mirror. Although the invention is illustrated withbreakaway joint 44, the invention may also be applied to mirrors thatare rigidly mounted to the vehicle.

An alternative vehicle personal security lighting system 25′ includes alight module 104 that is removably positioned within housing 34′ ofexterior mirror assembly 26′ (FIG. 21). In addition to the opening foraccepting bezel or cowling 106, mirror housing 34′ includes a downwardopening 108 for receiving light module 104. Additionally, bezel 106includes a recess 110 which defines an opening facing generallydownwardly and rearwardly of the vehicle. Exterior mirror assembly 26includes a bracket 43′ for mounting positioning device 42 which mountsreflective element 28. Bracket 43′ has two pairs of flexible prongs 112,which are received within sockets 114 defined on an enclosure 116 oflight module 104. Prongs 112 releasably engage sockets 114 in order toretain the light module within the exterior mirror assembly in openings108 and 110. Light module 104 may be disassembled from exterior mirrorassembly 26′ by reaching behind reflective element 28 with a pair ofneedle-nose pliers, or the like, and sequentially compressing each ofthe pairs of prongs 112 in order to release the prongs from sockets 114.Thus, prongs 112 and sockets 114 provide a fastener-less system whichretains the light module in the exterior mirror assembly without the useof separate fasteners. A pair of shoulders 118, which define a slot 120therebetween, engage a protrusion from an inner surface (not shown) ofhousing 34′ in order to assist in stably positioning light module 104within housing 34′. Alternatively, one or more fasteners, such asscrews, clasps, latches, clips, and their like could be used. But,preferably, for ease of serviceability and for consumer acceptability,only one, and at most two, such fastener should be used. A furtheradvantage of a fastener-less system is that it facilitates supply of alight module of this invention for use in a plurality of exterior mirrorassemblies manufactured by a multitude of exterior mirror manufacturerswith minimum modifications to the complete mirror assembly housing.

Unitary enclosure 116 has a generally downwardly directedlight-transmitting opening 122 and an opening 121 for receiving a lightsocket 124. Light socket 124 provides electrical connection to a lightsource 126, which is electrically interconnected to the vehicle througha cable 128. The socket may be self-gasketing, achieved by selection ofa material in its construction, at least at the mating surface, thatachieves a sealing function. Preferably, the socket, either wholly, orpartially at least at its mating surface, is a resilient, somewhatflexible polymer material, preferably with a durometer hardness,measured on the SHORE A scale of less than approximately 95, morepreferably less than approximately 85, and most preferably less thanapproximately 75 but preferably of SHORE A hardness greater than about50, and preferably greater than about 60. Materials appropriate toachieve this, and simultaneously have the physical, mechanical, and hightemperature performance needed, include silicone, urethanes,thermoplastic rubbers, and polyvinyl chloride. Preferably, the materialused for the self-gasketing socket is capable of withstandingtemperatures in use in excess of approximately 200^(N) F or higher.Alternatively, a rigid construction may be used for the light socket,such as a ceramic, engineering plastic, Bakelite, nylon, polyester,filled polyester, or filled (glass and/or mineral) nylon, if a gasketingmaterial delivering the above properties are used at the point of matingof light socket 124 and enclosure 116. Light socket 124 seals againstenclosure 116 by the provision of a gasket, which, in the illustratedembodiment, is provided by the flexible nature of light socket 124.Alternatively, a separate gasket member formed of material such assilicone, neoprene, thermoplastic rubber, EPDM, polypropylene/EPDM alloyand similar elastomeric materials, preferably having the hardnessproperties listed above, could be inserted between the light socket andthe enclosure. Light-transmitting opening 122 is covered by a covermember 130. Cover member 130 is a lens member, which affects thedistribution of light emitted from light source 126. In the illustratedembodiment, cover member 130 is a clear optic lens that provides asubstantially uniform puddle of light on the illuminated area adjacentthe vehicle's door having a relatively wide light pattern, or floodpattern. Alternatively, cover member 130 could be a diffractive optic, adiffusive optic, a refractive optic, a reflective optic, a holographicoptic, a binary optic, or a sinusoidal optic. In the illustratedembodiment, light source 126 is an incandescent lamp that is a filamentoptic having a minimum five-candle power. Such candle power mountedwithin an exterior mirror assembly of an automobile will preferablyproduce a ground surface illumination intensity of at leastapproximately 5 lux or greater, more preferably at least about 10 lux,and most preferably at least about 20 lux. Light source 126 may range inpower up to 32-candle power or more. The preferred range is betweenapproximately 5-candle power and approximately 15-candle power. It isdesirable to provide as much candle power as possible without creatingexcessive heat within enclosure 116. If a high wattage lamp is used, aventilation system is provided. Ventilation techniques are known in theart which allow the passage of air through the cavity 134 in which thelight source is positioned while providing a substantiallymoisture-impervious barrier.

Light module 104 additionally includes a reflector 132 surrounding lightsource 126, both positioned in a cavity 134, which extends tolight-transmitting opening 122. The purpose of the reflector is in orderto direct the light from light source 126 into the pattern of lightillustrated in FIGS. 10-12. Reflector 132 may be a parabolic reflector,as illustrated in FIG. 23, but may additionally include an extendedtunnel in order to provide collimation of the light beam. In theillustrated embodiment, reflector 132 is aluminum or high efficiencyaluminum vacuum-deposited on a wall 133 defining cavity 134, with anoptional coating of lacquer. Alternatively, wall 133 may be coated witha white paints such as “Argent” white or a silver paint. Reflector 132may be a separate member, such as stamped metal or an aluminized glassoptic. Alternatively, light source 126 and reflector 132 may be providedas an assembly.

Light module 104 includes a second cavity 140 defined in enclosure 116and extending to a second light-transmitting opening 136. A signal lightassembly 138 is positioned within cavity 140 to radiate light rearwardlywith respect to the vehicle. Signal light assembly 138 includes a pairof electrical contacts 142, which protrude through grooves 144 definedin a flange 146 surrounding opening 136. Contacts 142 engage a connector148, which provides electrical connection between signal light assembly138 and the vehicle through cable 128 which, in turn, may piggyback orotherwise connect to existing 12-volt battery/ignition wiring alreadysupplied in the housing to service an electrical actuator and/or adefroster heater pad.

Signal light assembly 138 includes a plurality of light-emitting diodes152 positioned on circuit board 150. A variety of emitting sources maybe used as light-emitting source 90, including, but not limited to, veryhigh intensity amber and reddish-orange light-emitting diode (LED)sources, such as solid-state light-emitting diode (LED) sourcesutilizing double heterojunction AlGaAs/GaAs material technology, such asvery high intensity red LED lamps T-1¾ (5 mm) HLMP-4100/4101, availablefrom Hewlett Packard Corporation, Palo Alto, Calif., or which usetransparent substrate aluminum indium gallium phosphide (AlInGaP)material technology, commercially available from Hewlett PackardCorporation, Palo Alto, Calif. under the designation T-1¾ (5 mm)HLMT-DLOO, HLMT-CHOO, HLMT-CLOO, HLMT-CH15, HLMT-CL15 and HLMT-DHOO orhigh power AlInGaP amber and reddish-orange lamps under the designationHLMA-CHOO/-CLOO, HLMA-DGOO/-DHOO/-DLOO, HLMA-EH20/-EL20,HLMA-KHOO/-KLOO, and HLMA-QHOO/-QLOO, or which use InGaAlP materialtechnology available from Toshiba Corporation of Latham, N.Y., such asunder the designation TLRH180D or GaAlAs/GaAlAs LED sources availablefrom Sharp Corporation Electronics Components Group such as Model No.GL6UR31 T and Model No. GL6UR3T which are red LEDs. Light emittancecolors provided by such solid-state sources include orange, yellow,amber, red, and reddish-orange, desirably without need of ancillaryspectral filters. The preferred solid-state light-emitting diodes, at25^(N) C or thereabouts, operate at a forward voltage of about 2 voltsto about 5 volts; have a luminous intensity (measured at the peak of thespacial radiation pattern which may not be aligned with the mechanicalaxis of the source package) of a minimum, at 20 mA current, of about 500to about 5000 mcd (typical, about 700 to about 7000 mcd); operate at aforward current of about 20 mA to about 50 mA; emit with a dominantwavelength (CIE Chromaticity Diagram) of about 530 nm to about 680 nm;and have a viewing angle 202 (where Θ₂ is the off-axis angle where theluminous intensity is one half the peak intensity) of about 5^(N) toabout 25^(N).

A lens assembly 154, which may be a polycarbonate or acrylic material,is positioned over signal light assembly 138. Lens assembly 154 mayinclude a clear or sinusoidal optical surface 156 and a plurality oflouvers 158. Louvers 158 and light-emitting diodes 152 are skewed awayfrom the passenger compartment of the vehicle. In the illustratedembodiment, the light-emitting diodes and louvers are skewed at an angleof at least approximately 15^(N), more preferably approximately 20^(N),and most preferably approximately 25^(N) to 30^(N) from the longitudinalcenterline of the vehicle, but preferably not more than about 45^(N).The purpose of the skewing is in order to allow the light radiated bythe signal light assembly to be visible by drivers in vehicles to theside of vehicle 40, but to be shielded from the driver of the vehicle40. This features prevents distraction to the driver of the vehicleequipped with the security lighting system. A cover member 160 enclosessignal light assembly 138 and sinusoidal optical surface 156 bymoisture-tight engagement with flange 146 of enclosure 116. In theillustrated embodiment, light-emitting diodes 152 are individuallymounted at an angle on circuit board 150. In an alternative embodiment,light-emitting diodes 152 could be mounted upright, normal to circuitboard 150, with the entire signal light assembly mounted at an anglewith respect to the vehicle passenger compartment in order to provideproper skewing away from the driver of the vehicle equipped with themirror assembly security system according to the invention. Also, whendesired, a current limiting resistor can be mounted on circuit board 150in series with the light-emitting diodes 152 to limit currenttherethrough and to mate to the 12-volt ignition/battery potentialservicing the exterior mirror assembly.

Enclosure 116 is made from a heat-resistant material and issubstantially moisture impervious. Preferably, a polymer material isused which has a heat distortion temperature (as measured by ASTM D 648for a 12.7×12.7×6.4 mm specimen and at 1820 kPa) of at leastapproximately 80^(N) C, more preferably at least approximately 100^(N)C, and most preferably at least approximately 120^(N) C. Amineral-filled or glass-filled nylon or polyester or acrylonitrilebutadiene styrene (ABS) polymer may be utilized for enclosure 116. Inthe illustrated embodiment, enclosure 116 is made from polycarbonatewith cover members 130 and 160 made from a polycarbonate or acrylic. Thecomponents of enclosure 116 may be assembled by conventional sonicwelding, vibration welding, or by the use of suitable adhesives.Enclosure 116 is opaque, except for cover members 130 and 160, in orderto shade light. The light module fits within the cavity defined withinhousing 34′ by openings 108 and 110 in a manner which conforms to thestyling and aerodynamic lines of the housing.

In an alternative embodiment illustrated in FIG. 25, a light module 104′is provided that includes a first downwardly directed light-transmittingopening 122 but does not include a rearwardly directedlight-transmitting opening in the housing bezel. Light module 104′provides a puddle of light around the vehicle's doors, but does notinclude a signal light visible by drivers on the sides of the vehicle 40equipped with light module 104′. In this manner, a mirror assemblysecurity system, according to the invention, may be provided with agenerally downwardly directed security light alone (104′) or incombination with a signal light (104), which may illuminate in unisonwith the vehicle's turn signal, or brake lights, or both. Alternatively,signal light 104 may be provided as a stand-alone module packaged suchas described herein and achieving the advantages in terms of modularity,ease of service/installation, weather resilience, etc., describedherein. Thus, it is seen that the present invention provides anexceptionally flexible design which is easily adapted to variousconfigurations desired by the vehicle manufacturers. Additionally,because the security system is provided in a unitary module having aunitary cover member/lens, the invention may be readily adapted to manyvehicle housing designs without requiring extensive re-engineering ofthe vehicle exterior mirror housing.

In another embodiment, a light module 104″ includes side-by-sidecavities 134′ and 140′ (FIGS. 26-28). Cavity 134′ terminates in alight-transmitting opening 122′, which extends both downwardly andrearwardly with respect to the vehicle. A light-directing lens, orprism, 162 in cavity 134′ captures a portion of the light radiated bylight source 126′ and directs it rearwardly of the vehicle. The puddleof light produced by light module 104″ is capable of extendingrearwardly of the vehicle because of the nature of light-transmittingopening 122′ and the light redirecting effect of prism 162. The secondcavity 140′ in enclosure 116′ includes a light-transmitting opening 136′which extends generally rearwardly of the vehicle. A light source 138′is positioned within cavity 140′ and is surrounded by a reflector 164,which directs light through light-transmitting opening 136′. A diffuserassembly 154′ includes an integral cover member and louvers in order todirect light radiated by light source 138′ away from the passengercompartment of the vehicle equipped with light module 104″. A unitarycover 130′ extends over both openings 122′ and 136′. Enclosure 116′includes a surface 166, which is configured with a groove 168, whichmates with a tongue (not shown) in housing 34″ of mirror assembly 36″.The mating tongue-and-groove surface configuration is repeated on thesurface of enclosure 116′, which is opposite surface 166. Thetongue-and-groove configuration at least partially retains light module104″ within housing 34″ with a fastener, such as a threaded fastener169, between an opening in housing 34″ and extending into enclosure116′. In the illustrated embodiment, light radiated from light source126′ through light-transmitting opening 122′ provides a puddle of lightadjacent the vehicle doors in order to produce a lighted security zone.The light radiated through light-transmitting opening 136 produced bylight source 138′ provides a signal indicator, which may be a turnsignal indicator, or a brake signal indicator, or both a turn signal andbrake signal indicator.

In another embodiment, a light module 104′″ includes a removablefastenerless attachment system 170 including a first member 172 mountedto bracket 43″ and a second member 174 mounted to enclosure 116′ (FIGS.29-31). First member 172 is a clip connector having a pair of guidemembers 176 a, 176 b and a retaining prong 178 overlaying the guidemembers. Second member 174 includes a wall 180 defining a doghouse typereceiving connector. Guide members 176 a, 176 b assist the sliding entryof first member 172 into the cavity defined within wall 180 so thatprong 178 engages the wall to retain the clip within the cavity.

With fastenerless attachment system 170, module 104′″ is easily andreadily mounted by a simple insertion into the receiving opening in themirror housing such that the first member is received by and engagedwith the doghouse style receiving connector of the second member. Toremove module 104′″ for service, a tool, such as a flathead screwdriver,is inserted in the gap between the mirror element and the lamp moduleand prong 178 is raised, using a lift and twist motion, while the moduleis being pulled outwards from the mirror housing.

In a preferred embodiment, the lamp module of this inventionincorporates a signal light that is a 12-watt #912 incandescent lightsource available from OSRAM/Sylvania, Hillsboro, N.H. (with about12-candle power when operated at about 12.8 volts) mounted in aself-gasketing socket available from United Technologies Automotive,Detroit, Mich. under the trade name E25B-13A686-BA and fabricated of anelectrical grade polyvinyl chloride injection molding compound such asto comply with Engineering Standard ESB-M4D317-A of Ford Motor Company,Dearborn, Mich., which is hereby incorporated herein by reference orfrom a thermoplastic rubber self-gasketing socket. The socket, in turn,is housed in a unitary enclosure, as described herein, fabricated ofheat resistant polycarbonate supplied by General Electric Plastics,Woodstock, Ill. under the trade name ML4389 and meeting Ford EngineeringSpecification ESF-M4-D100-A, which is hereby incorporated herein byreference. The lens is made of acrylic supplied by General ElectricPlastics under the 141-701 trade name. The LEDs in the signal light, ofwhich six are used, are HLMA-DGOO high power AlInGa solid-statelight-emitting diodes supplied by Hewlett Packard Corporation with adominant wavelength at 622 nanometers, a peak wavelength at 630nanometers, a 30^(N) viewing angle, and a typical luminous efficiency,at 25^(N) C, of 197 lumens/watt. When incorporated into an exteriormirror housing and mounted on a typical automobile, the groundillumination lamp height is approximately 30 ∀5″from the ground surface,and, when operated at about 12 volts, the lamp light source illuminatesan approximately 2-foot by 4-foot or thereabouts ground area adjacentthe vehicle with a light level of at least about 10 lux and an averagelight level of approximately 40 lux.

Light modules of this invention, including a ground illumination lampand a signal light incorporated into an exterior mirror assembly, weremounted and driven on vehicles through a variety of driving conditionsand through varied environmental exposure, and were found to have theperformance and environmental resilience required by automakers so as tobe suitable for commercial use on vehicles.

Although illustrated herein as being located along the bottom rim of theexterior trim housing, other locations are possible for the signal lightof the invention, including the top and outboard rim of the exterior rimhousing, and even elsewhere on the exterior vehicle body as appropriate.

Should it be desired to vary the intensity of the signal lights so theyare brightest during high ambient lighting conditions, such as on asunny day, but so that they are dimmer when ambient conditions arelower, such as at night, the intensity of signal light can be modulatedusing a photosensor such as a photoresistor, photodiode,phototransistor, or their like. A photosensor that controls theintensity of the signal light so that it reduces its intensity duringlow ambient light driving conditions, such as by pulse width modulationon the electrical line powering the LEDs in the signal light, may bemounted integrally with the lamp module itself, or it may be part of thevehicle electronics itself, such as a photosensor mounted as a part ofan automatic electrochromic mirror circuit, as part of a vehicleautomatic headlamp activation circuit, as part of a headlamp daylightrunning light control circuit, or their like.

Also, the concepts of this invention are applicable to a variety ofexterior vehicular mirror assembly constructions, including one-partdesigns, uni-body constructions, and their like, as known in theexterior mirror assembly art. The concepts of the invention areapplicable to a variety of assemblies including assemblies that use abracket as a distinct internal structure and assemblies that do not usea bracket but rather are bracket-less assemblies where the housingitself serves as a structural element with means such as on the walls ofthe housing for securing an actuator and for receiving a lamp module.

Also, although desirably and preferably finding utility as a securitylight, the exterior mirror assembly light modules of this invention arealso useful for other purposes such as providing for a courtesy exteriorlight and a general ground illumination light when such lighting may bedesired such as when a door is opening, a key is inserted, or a keyboardentry is touched, or when approach of a person to a vehicle is detectedsuch as by voice activation, proximity detection and their like. Also,light modules using the principles and concepts described herein couldbe provided for mounting on the vehicle other than within an exteriormirror assembly, such as under a door within a door well or under a doorbody panel so as to provide ground illumination directly under a doorwhenever said door is opened.

Changes and modifications in the specifically described embodiments canbe carried out without departing from the principles of the invention,which is intended to be limited only by the scope of the appendedclaims, as interpreted according to the principles of patent lawincluding the doctrine of equivalents.

1. A mirror assembly security system for a vehicle comprising: a firstexterior mirror assembly including a first reflective element and afirst housing for said first reflective element; a first light moduleremovably positioned in said first housing, said first light moduleprojecting light from said first housing on at least a first areaadjacent a first portion of the vehicle in order to create a firstlighted security zone in said first area; and said first light moduleincluding a first enclosure, a first light-transmitting opening in saidfirst enclosure facing at least one of generally downwardly andrearwardly of said vehicle, a first cover for said firstlight-transmitting opening, and a first light source in said firstenclosure radiating light through said first light-transmitting opening.